Ref Number: ACSB/SKO/W/SUM/1
SARAWAK OPERATIONS
WORKPACK
ACTIVITY
PLATFORM
EQUIPMENT
WO NUMBER
PERSONNEL
PREPARED BY:
REVIEWED BY:
ENDORSED BY:
:
:
:
:
SWITCHGEAR & MCC MAINTENANCE
TEMANA PLATFORM
GS100, MCC-100, MCC-101
NAME
Mohammad
Yusmin
Azmi Ahmad
POSITION
ACSB
ENGINEER
ACSB
MANAGER
M Syakiq Mat
Sihat
PCSB ENGINEER
BME Manager
PCSB MANAGER
SECTION HEAD
APPROVED BY:
SUMANDAK OIM
SIGNATURE
DATE
TABLE OF CONTENTS
1
INTRODUCTION
1.1
1.2
1.3
Field Background
Project Background
Equipment Details & Specifications
2
2
2
3
2
DETAILED WORK SCOPE
2.1
Work Procedure
2.2
Work Planning
4
4
11
3
MANPOWER LOADING
3.1
Manpower List
3.2
Organization Chart
3.3
PCSB Focal Person
3.4
HSE Requirement
3.4.1
Toolbox Meeting
3.4.2
PTW
3.4.3
JHA
14
14
14
15
15
15
15
15
4.1
4.2
TOOLS & MATERIALS LIST
Tools & Parts Require
Lifting Plan
17
17
18
5.1
PROJECT DETAILS
Project Schedule
21
21
APPENDICES
21
4
5
6
2
1 INTRODUCTION
1.1
Field Background
Temana Platform
1.2
Project Background
This shutdown maintenance and services of the switchgear and MCC at Temana
platform is to maintain the equipment as per routine activity as per below:
a) Shall perform visual inspection for damage, overheating, corrosion, cracked
insulation and loose terminals.
b) Shall perform general cleaning on switchgear (ACB, MCC, busbar,
compartment, etc).
c) Shall perform insulation resistance for contactor and circuit breaker.
d) Shall perform continuity check by measuring closed contact resistance of
contactor.
e) Shall verify conductivity, continuity and integrity of the busbar assembly,
switchgear earthing and bonding.
f) Shall perform functional check on switchgears and MCC inclusive of control
systems and electrical/mechanical interlocks.
g) Shall verify the ACB and MCC panels operation and interlocks.
h) Shall verify the control wiring system against the schematic diagram.
i) Shall inspect and service MCC contactors and circuit breakers for condition,
alignment and correct setting.
j) Shall troubleshoot and rectify any switchgear and MCC having abnormalities.
k) Shall perform testing and recording data.
l) Shall perform tightening for any losing part.
m) Shall perform cleaning
3
1.3
Equipment Details & Specifications
Lists below show the switchgears and MCC involved during shutdown maintenance:
4
2 DETAILED WORK SCOPE
2.1
Work Procedure
2.1.1ACB Panel Servicing & Testing
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
xix.
xx.
PTW and IEC Cert shall be approved by PCSB before work
commences.
Switching (De-energize) to be done by PCSB Chargeman.
Contractor to confirm no supply from ACB using HV Test Pen.
Switchgear Panel to be placed at the Earth Position. Before inspecting
or performing any maintenance on either the breaker or its
mechanism, be sure the breaker is in the open position. Both the
closing and opening, springs should be discharged or blocked
mechanically before any maintenance is done.
Compare nameplate data with drawings and specifications.
Inspect circuit breaker for correct mounting.
Operate circuit breaker to insure smooth operation.
Inspect case for cracks or other defects.
Inspect all bolted electrical connections for high resistance.
Inspect mechanism contacts and arc chutes in unsealed units.
Inspect anchorage, alignment, and grounding. Inspect moving and
stationary contacts for condition, wear, and alignment.
Perform a contact-resistance test. Microhm drop values shall not
exceed the high levels of the normal range as indicated in the
manufacturer’s published data. If manufacturer’s data is not available,
investigate any values which deviate from similar connections by
more than 50 percent of the lowest value.
Perform an insulation-resistance test at 1000 volts dc from pole-topole and from each pole-to-ground with breaker closed and across
open contacts of each phase. Circuit breaker insulation resistance
should be in accordance with attached appendices table for minimum
IR value.
Clean the area of arc chutes until thoroughly clean and ensure the arc
chutes are clear of contamination and have no significant damage on
grids or ceramics.
Perform cleaning and lubricate the ACB contacts (aux, finger) and
linkages
Determine IR and contact resistant measurement after servicing.
Check on earthing system, alignment and rack condition.
Report on abnormal findings immediately to PIC.
Check for leftover tools and consumables.
Rack in the breaker to service position.
5
2.1.3 MCC Servicing and Testing
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
PTW and IEC Cert shall be approved by PCSB before work
commences.
Compare equipment nameplate data with drawings and
specifications.
Inspect physical and mechanical condition.
Inspect all bolted electrical connections for high resistance
Test all interlocking systems for correct operation and sequencing.
Inspect all indicating and control devices for correct operation.
Perform cleaning and servicing on contact, surface, internal
component and structural of MCC & proper lubrication.
Perform insulation-resistance tests on each pole, phase-to-phase and
phase-to-ground with switch closed and across each open pole for
one minute. Test voltage and minimum insulation resistance shall be
in accordance with manufacturer’s published data or attached table
on appendices
Report on abnormal findings immediately to PIC.
Check for leftover tools and consumables.
2.1.4 Busbar Servicing and Testing
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
PTW and IEC Cert shall be approved by PCSB before work
commences.
Switching (De-energize) to be done by PCSB Chargeman.
Contractor to confirm no supply from busbar using HV Test Pen.
Before perform electrical test, ensure the entire load (breaker, MCC,
CT, VT and fuses) to busbar is disconnected.
Compare equipment nameplate data with drawings and
specifications.
Inspect busbar for physical damage and correct connection in
accordance with single-line diagram.
Inspect all bolted electrical connections for high resistance.
Verify tightness of accessible bolted electrical connections by
calibrated torque-wrench method
Measure insulation resistance of each busbar, phase-to-phase and
phase-to-ground for one minute. Insulation-resistance test voltages
and resistance values shall be in accordance with manufacturer’s
published data or attached table on appendices. Minimum resistance
values are for a nominal 1000 foot busbar run.
Perform contact-resistance test on each connection point of noninsulated busbar. Compare bolted connection resistances and bus
joint resistances to values of similar connections. Microhm drop
values shall not exceed the high levels of the normal range as
6
xi.
xii.
xiii.
xiv.
xv.
xvi.
indicated in the manufacturer’s published data. If manufacturer’s data
is not available, investigate any values which deviate from similar
connections by more than 50 percent of the lowest value.
Perform general cleaning on busbar
Apply all new silicon sealant to all busduct joint and gasket.
Measure IR and contact resistance after service.
Report on abnormal findings immediately to PIC.
Check for leftover tools and consumables.
Closed the busbar compartment.
2.1.5 Testing Procedure
A. Insulation Resistance Test
Procedure before Performing Insulation Resistance Test
i.
ii.
iii.
iv.
v.
The system or equipment is taken out of service and disconnected
from all other circuits, switches, capacitors, brushes, lightning
arrestors and circuit breakers. (Make sure the measurements are not
affected by leakage current through switches and over current
protective devices.
The temperature of the conductor is above the dew point of the
ambient air. When this is not the case, a moisture coating will form on
the insulation surface and in some cases will be absorbed by the
material.
The surface of the conductor is free from carbon and other foreign
matter that can become conductive on humid conditions.
Applied voltage is not too high when testing low voltage system. Too
much voltage will damage the insulation.
The system under test needs completely discharged to the ground.
The grounding discharge time should be about five times the testing
charge time.
Safety Procedure on Insulation Resistance Test
i.
ii.
iii.
iv.
Never connect the insulation tester to energized conductors or
energize equipment and always follow manufacturer’s
recommendation.
Shut down the equipment to be tested by opening fuses, switches and
circuit breakers.
Disconnect the branch circuit conductor, grounding conductor and all
other equipment from the unit under test.
Discharge conductor capacitance, both before and after the test. Some
instrument may have automatic discharge functions.
7
v.
vi.
vii.
Check for any leakage current through fuses, switches and breakers
on de- energized circuits. Leakage current can cause inconsistent and
incorrect reading.
Do not use an insulation tester in dangerous or explosive atmosphere
since the instrument can generate arching in damaged insulation.
Use insulated rubber glove when connecting the test lead.
Procedure of Insulation Resistance Test
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
Use multimeter or voltmeter to make sure there is no power applied
to the tested circuit.
Set the voltage level to as per table attached on appendices depend on
equipment. E.g. 1000V for LV switchboard (ACB, MCC) and 2500V for
MV switchboard (VCB).
Plug one end of the black test lead to the common terminal on the
meter end and touch the test probe to the ground or another
conductor. Sometimes it is helpful to ground all conductors that are
not part of the test.
Plug one end of the red test lead to the volt/ohm terminal on the
meter and connect the test probe to the conductor to be tested.
Press the test button to apply the desired voltage and read the
resistance display on the meter. It could take a few seconds for the
reading to be settled. The higher the resistance the better.
Test the insulation between phase to phase and phase to neutral as
per checklist.
Keep a dated record of the measured value.
If some of the conductors fail the test, identify the problems and take
necessary actions. Moisture, water and dirt can create low resistance
readings.
8
Figure 1: Connection Diagram of CB Insulation Resistance Test
Figure 2: Connection Diagram of Busbar Insulation Resistance Test
9
B. Micro-ohm Measurement/Contact Resistance/Ductor Test
Procedure Performing Contact Resistance Test
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
Make certain that the circuit breaker is de-energised on both sides, closed
and safety grounded and that local safety regulations are followed.
Ground the test instrument.
Make sure that the test instrument is switched off.
Connect current and sensing cables according to the drawing.
Switch the test instrument on.
Set the test current to minimum 100A (according to ANSI C 37.09)
Perform the measurement.
Repeat the test on the different phase.
Figure 3: Connection Diagram of Ductor/Contact Resistance Test
10
2.2
Work Planning
2.2.1 Shutdown activity
Day
Work Description
1
-
Arrival at Temana Platform
Apply for PTW, ensure isolation certificate in place, and prepare
the worksite.
ET : 2 hrs
-
Do a toolbox meeting prior to the job.
Barricade the work area to prevent unauthorized personnel enter
the area.
Ensure system is disconnected from all electrical sources and do a
proof test to ensure system is totally dead.
ET : 1 hr
-
-
Shutdown activities: To perform servicing on busbar and dropper
on switchgear GS-100 as per work scope and listed as per table
below:
Busbar
ET : 4 hrs
ACB
ET : 3 hrs
2
-
-
Plan Man
Hours
12 hrs
GS-100 busbar
1. ACB G700 Gas Generator
2. ACB G710 Diesel Generator
3. ACB Bustie
Housekeeping and apply PTW for next day activities and submit
report to PIC.
ET : 1 hr
Arrival at Temana Platform
Apply for PTW, ensure isolation certificate in place, and prepare
the worksite.
ET : 2 hrs
12 hrs
Do a toolbox meeting prior to the job.
Barricade the work area to prevent unauthorized personnel enter
11
-
-
the area.
Ensure system is disconnected from all electrical sources and do a
proof test to ensure system is totally dead.
ET : 1 hr
Shutdown activities: To perform servicing on busbar and MCC at
switchgear MCC100 as per work scope and listed as per table
below:
Busbar
ET : 4 hrs
MCC
ET : 4 hrs
3
-
-
Busbar MCC100
15 units MCC
2 units Isolator Switch
Housekeeping and apply PTW for next day activities and submit
report to PIC.
ET : 1 hr
Arrival at Temana Platform
Apply for PTW, ensure isolation certificate in place, and prepare
the worksite.
ET : 2 hrs
12 hrs
Do a toolbox meeting prior to the job.
Barricade the work area to prevent unauthorized personnel enter
the area.
Ensure system is disconnected from all electrical sources and do a
proof test to ensure system is totally dead.
ET : 1 hr
Shutdown activities: To perform servicing on busbar and MCC at
switchgear MCC101 as per work scope and listed as per table
below:
Busbar
Busbar MCC100
ET : 4 hrs
15 units MCC
MCC
ET : 4 hrs
2 units Isolator Switch
-
Housekeeping and apply PTW for next day activities and submit
report to PIC.
ET : 1hr
12
4
-
Ensure PTW and isolation certificate in place, and prepare the
worksite.
ET : 1 hr
-
Do a toolbox meeting prior to the job.
Barricade the work area to prevent unauthorized personnel enter
the area.
ET : 1 hr
-
Post-Shutdown activities: To perform servicing on remaining VCB,
VCU, ACB and MCC and also perform thermography on switchgear
SG-7510. SB7710 and SB-7720.
ET : 8 hr
-
Housekeeping and apply PTW for next day activities and submit
report to PIC.
ET : 1hr
3 MANPOWER LOADING
3.1
Manpower List
Below is the list of manpower for site work activities:
No. Name
Designation IC No.
1
2
3
4
5
Engineer
Mohammad Yusmin
Dianto Rasali
Technician
Muhd Daud Abd Wahab Technician
Roslan Abu Bakar
Technician
811006035183
HUET
Expiry Date
09/03/2014
Medical
Expiry Date
01/01/2012
851231495617
860804295327
801123115271
26/01/2014
17/08/2013
28/06/2012
17/01/2012
05/09/2011
29/06/2012
13
6
Mohd Sabri Abdul Ghani Technician
3.2
Organization Chart
3.3
PCSB Focal Person
811218115441
16/05/2012
21/05/2012
Muhammad Syaqiq Bin Mat Sihat,
Maintenance Department (BME-5),
PCSB-Sarawak Operation
Tel
: 085-475874
Mobile : 013-7112301
syaqiq_matsihat@petronas.com.my
3.4
HSE Requirement
3.4.1 Toolbox Meeting


Work leader will briefly discuss the work plan.
Possible injuries from Electricity such as
 Dangers from electricity:
14


Voltage can cause ventricular fibrillation (stop heart
function).
 Current flow can cause severe burns.
 Reaction to Electric Shock (varies and can depend on)
 Voltage level and duration
 Physical condition of victim
 Contact area with voltage
 Victim skin condition
 Ambient conditions
Before carrying out the switching work, several safety precautions
has to be observed such as,
 Isolation / switching must be performed by competent /
authorized person.
 Ensure the breaker/MCC is dead before carrying out any
maintenance.
 Care should be taken when withdrawing and removing
breaker/MCC carriage.
 Breaker/MCC servicing should be performed by a team of
at least 2 persons.
3.4.2 Permit to Work


The objective of electrical work permits is to establish safe working
practices by
 Defines responsibilities
 Specifies the work & time period the permit is valid
 Precautions to be taken for the work
 Defines safe working limits to avoid DANGER
 Defines procedures to be followed
 Identifies any special equipment, tools or clothing
A few people of ASAGA personnel who involved with this turnaround
maintenance attend PETRONAS Carigali PTW Applicant course.
3.4.3 Job Hazards Analysis
See Attachment on appendices for JHA
15
4 TOOLS & MATERIAL LIST
4.1 Tools & Parts Required
No
Description
1
IR Tester 1kV
2
Contact Resistance Tester
3
Digital Multimeter
4
Test plug
5
Digital clamp meter
6
Discharge Rod
7
Blower
8
Vacuum Cleaner
9
Common Tools (Tools bag)
10
Long nose pliers 8 inch
11
Locking pliers 8 inch
12
Adjustable spanner 8 inch
13
Adjustable spanner 12 inch
14
Iron saw with blade
15
Iron saw with blade small
16
Flat file (Kikir)
17
Round file (Kikir)
18
Steal brush
19
Cable snapper
20
Common Spanners set
21
Power Extension Cords
22
Torchlight (explosion proof)
23
Torque Wrench (8-60 Nm)
24
Cordless Drill (12 Volt)
25
Paint brush
26
Digital camera
27
WD-40
28
Contact Cleaner
29
3M Tape
30
Cotton Rag
31
Sand Paper
32
Teflon Tape
33
Cotton Hand Glove
34
Masking Tape
35
Plastic Bag
36
PVC Tape (Red, yellow, blue, black & green)
37
Cable/busbar cleaner
38
Barricade tape
Quantity
3
1
2
1
2
1
1
1
2
2
2
4
2
2
2
2
2
2
2
2
2
1
1
1
1
1
4
4
4
1 pack
4
1 pack
1 pack
4
1 pack
6 each
4
2
16
4.2
Lifting Plan
During the turnaround activity, ASAGA team will bring a numbers of boxes and need a
crane service to carry the loads to the platform. The dimension and estimated weight of
the boxes as illustrated below.
ITEM 1
BOX 1: Tools and Test Equipments
Dimension
Estimated weight
: 24” x 54” x 22”
: 50kg
ITEM 2
BOX 2: Tools and Test Equipments
Dimension
Estimated weight
: 27” x 55.5” x 18”
: 50kg
17
ITEM 3
BOX 3: Tools and Test Equipments
Dimension : 17” x 21” x 15”
Estimated weight
: 25kg
ITEM 4
BOX 4: Contact Resistance Tester
Dimension
Estimated weight
: 19” x 22” x 10”
: 20kg
18
ITEM 5
BOX 5: Plastic Container
Dimension
: 19” x 22” x 10”
Estimated weight : 20kg
ITEM 6
2x Fiber Ladder
19
5 PROJECT DETAILS
5.1
Project Schedule
20
6 APPENDICES
6.1
6.2
6.3
Job Hazard Analysis
Single Line Drawing
QA/QC Plan - Checklist
21